Method and apparatus for opening fibrous agglomerations



Sept. 2, 1952 J. H. ZETTEL 2,609,313

METHOD AND APPARATUS FOR OPENING FIBROUS AGGLOMERATIO NS Filed July 26, 1947 I 7. Joseph H. Zeffel.

A TORNEY.

Patented Sept. 2, 1952 v s PATENT. y I 2-,6Q,s1a Y "METHOD AND .nnPARATUs Toner-sumo FIBROUSAGGLOMERATIONS I zloseph .zH, .zettelnMartinsville, N. .J,., assignorn-to :JohnseMa-nville:Gorpozation,..New .lork, .-.Y., :a corp orationtoi New York r I The instant invention-. relates to a method and apparatus for opening and tut-ting fibrous a'gglomerations or nodules? and, more particularly, isdire'cted to -the openmg andifiutfing, of nodules of mineral "wool and li-ke fibrous materiazls. The

opened, 1 fluff ed nodules 'find a principal held of use :as :a component zmateria-l "for -minera'l wool dilarikets or: blocks but they maybeemployedfior other purposes.v As'the term imineral -wool' is 'employed herein :it =is intended to include fibers formed; from. rock, :s1a'g, glass, 2 mixtures thereof, 'zandtlikea mineral materials. subject to conversion intolfibrous iform. I iRelativelyirigidimineral wool lolocks-andxblan- :lcetszforinsulation and .:other purposes. have'been 'tmadezinga numherzofwayaxand recent :develop- :ments inp'the construction 20f iimprovedzmaterials of. this-typeinvolveithe utilization of the mineral wool-innodular or: agglomerate' form; thernodnles containing a binding material. In the formation of ;;the product :the nodules arezdistributedzon a conveyor or iother :receiving surface .tociorm .a lawn and this. layeriscompressedtandi the-binder theme-activated and set -wherebyza unitary.;prod- .uc-t. is obtained in which the binderaserves rto'secure the modules into coherent gsheet form, .:as well as to bond the fibers in the individual-rhodules. The principal object of the instantainven- .tion'is'the provision of amethod and apparatus foropening and fiufljng nodules whereby, when used in such method, an improved interlocking between the. fibers of adj acent'nodu-les and-great- .er homogenity of the product are obtained. More specifically an object of the inventionzisithe provision of a method. andapparatusrfor subjecting :fibrousnodules containing a distributed binder or :other treating materialto aurubbing, :rolling and, shearing action to;open,.tuft.or fluff themand. also to secure amore :thorough distribution of the treating material over the :fibers.

Another object of the invention is the provision of an apparatus for :the .apurposes mentioned above, the apparatus including a cylindrical brush and a member adjacent the brush defining therewith .the confined zone through w-hich the :noduleszare carried. by rotation of the'bru'sh and =subjected during their passage to a --s'hearing, irolling v:and tearing action.

.-A .stilliurther objectof the invention is. the provisioncofra method and apparatus of the type Preferred 3170 above .whichperforms the: additional ziunctionof distributing the openednodul'eson-a conveyor :oruother receiving surface to :build 'up a :suhstantially uniform thickness layer.

My invention will be more' fully understood and siurther objects and advantages thereof will be- .ccome "apparent when reference is made 1 to the iollowing more detailed description .1 of "the :preifierred embodiment :of the invention -and to v the accompanying (drawings :in which:

9 Elaims. (01. 154-48) Fig. "1 sis-1a xiiagrammaticgside e1evationa1Wiew o-f :ancappara'tus'in .raccordanee with t the :inven tionand forzcarrying:.outz'the'methodithereof;

,i F-ig. '"12 is an'iendnelevational :VlfiWz'lGf. thei apaparatus; V

is. a sectionali View taken on. the line of Fig. 2; and, p

. Fig. aa ipartial sectional view illustrating a .modification of the apparatus.

:Referring .--now to the drawings, there :is--..diagrammatically shown -.-an -:apparatus -semhodying the 'invention: and for. carrying outthe method thereof, the apparatus including a cylindrical brush 1H! carried byva. shaft l2 supported in suit-- :able bearings lA mountedonrframe elements -16 ofithe machine. .I'heshattand roll aresadapted to be driven-in the direction indicated by the arrows inEigs. .1 ands by.anysuitablelmeans, .such as pulley 1-8, keyed-to an sextcnding end -or theshaft and .operatively connected to amotor .orother drive device (not. shown) by a be1t or chain 20. The brush.is preferablynrelatively and, .for this purpose has .bristles which also have the advantage of resisting the abrasive ac}- tionof the mineral wool. ".Thehrush maybe of any standard construction and may include a core-tor mandrel .sectionf22iin whichLthe bristles are secured. a

Referring nowppartioularly toFig."3,tamember .or "plate 124 of semi-cylindrical contoun 'at least on itsinner "face, suitably. an "arcuate tsectionof steel .pipe, is mounted adjacent to "the brush "to define .a .res'tricted'zone between *ityan'd -"-the-pe'- .riphcry of lthelorush; 'In the preferred embodimentthe zone" is of substantially uniform'depth throughout; that?is,theinner surface"of member j2'4"is :concentric"to the "brush. The depth of-"the zone .will depend upontheparficular type of agvg'lomerations :or modules "to The treated but for purposes of. example it may be "noted that for nodules 'or '"tufts or mineralwool, it has hem founcl'that a depth o f :about T /2"" "tof1-" is-'satis- .factory. The arcuate extent'of membe1' T4'-may also vary within reasonable "limits. half hire section of a 'd'iameter"I-""to 2". greater"than*the diameter of the brush and mounted .concentricallyto thei brush.hasbeenfo nd o urov o d results. .The ends of ,zone. 2'6 .may heclosed'as by end plates 23, oryif this section of) the-machine i enclosed; the side walls ofthe enclosure may serve this purpose.

At .or "adjacent "theiforwar'd end- "of m mber 2% a baffle or hp 2 9 'is'provided;-the" lipextendi-ng the full length of the brush and projecting approximately'ha'lf =thedepth-of the restrieted zone 'from member 2!. For example, where 'th'e depth 56f zone 26 is 1" th'e lip may -be :a steel harin thickness welded'tothe inner =surface of member 24 at its forward en'd. discharge portiill asidefinned between "the lip 2.9 and the brush: and

this location there may be an adjustably mounted deflector 'plate 32 adapted to control or direct the direction of discharge of the nodules issuing from between the brush and member 24. To permit the required adjustment, deflector plate 32 is preferably hinged as illustrated at 34 to lip 29 and a device is provided to secure the plate in any adjusted position. This may take the form of an arm 35 having an elongated, arcuate slot 38 to receive a thumb screw or other securing device 40 threaded into end plate 28 or other fixed element of the apparatus. It will be appreciated that any suitable adjusting device can be substituted for that shown.

The device for delivering the nodules to the confined zone 26 may be of any conventional type but in the form shown consists of an inclined chute 42 which permits the nodules to move by gravity into the zone. A receiving surface 44, usually a continuously traveling conveyor, is mounted below the apparatus to receive material discharged through port 30.

In the operation of the apparatus described above and in carrying out the method of the invention, nodules or agglomerations of mineral wool or other fibrous materials, preferably carrying a finely-divided or powdered treating material such as a powdered, phenol-formaldehyde resin binder intermixed therein, are deposited in trough 42 and discharged therefrom against brush roll in at the entrance end of zone 26 and are carried into said zone by rotation of the brush roll. The brush roll is driven in a direction (counter-clockwise in the construction shown) to carry the nodules into and through restricted zone 26. As the nodules pass through this zone they are subjected to a rolling, tearing and shearing action which tends to tuft or fluff them and open them. At the same time the shearing and tearing action serves to smear the binder particles on the fibers and to provide a better and more uniform distribution of the binder throughout the nodules. These effects on the nodules are accentuated by the action of baflle or lip 29. That is, as the material passes between the brush and member 24 a portion of it, and particularly small fibrous bunches and relatively individualized fibers and unfiberized material separated from the nodules build up behind the lip for a substantial distance to provide a rough surfaced body across which the nodules are drawn or raked in their passage to discharge port 30. The material piled up behind the lip will be gradually drawn through the port by the passage of the nodules over it but, inasmuch as it is immediately replaced by additional material, the rough surface is constantly maintained.

In some instances, particularly where tough fibrous material or tightly interlocked fibrous bunches or nodules are to be opened, it may be advisable to provide a roughened or toothed surface on the inner surface of plate 24. For example, as illustrated in Fig. 4, a material such as card clothing 46 may be used, the clothing being secured to the inner surface of the plate in any suitable manner. Enhanced shearing and tearing of the nodules is obtained by this modification.

The speed of the brush roll may vary substantially without seriously affecting the eflicient operation of the apparatus.v For example, speeds between300 and 1700 R. P. M. for 2. 12" diameter brush have been'found operable, although relatively lower speedsLsay between 300 and 700 R. P. M., are preferred to avoid excessive dustiness while still securing maximum effectiveness.

The opened nodules are discharged through port 30 with the forward impetus imparted to them by the brush roll. The normal trajectory of the nodules leaving the discharge port may be all that is necessary to provide satisfactory distribution for some purposes and, in such case, deflector plate 32 is not required. However, where a more positive control is desired, the deflector plate is adjusted to the angle required to direct the nodules through a trajectory which will insure a given distribution on receiving sur-- face 44.

The method and apparatus described above have been found particularly advantageous for use in connection with the production of blocks or blankets by the general process referred to above. When employed therein it has been found that superior products are obtained, even though the binder is originally imperfectly distributed in the fibrous nodules due, both to spreading of the binder on the fibers and the flufiing of the nodules. In the product, the projecting fibers of the tufted and flufied nodules interlock the nodules and, together with the improved distribution of the binder, result in a greatly increased modulus of rupture. As previously stated, although the invention is specially adapted for use in such process, it also may be incorporated in other processes where opened, flulfed nodules or agglomerations are desired. Also its use is not limited to the opening or finding of mineral wool nodules as it is applicable to other fibrous 11131381 ria s.

Having thus described my invention in rather full detail, it will be understood that these details need not be strictly adhered to but that various changes and modifications may suggest themselves to one skilled in the art, all falling within the scope of the invention as defined by the subjoined claims.

What I claim is:

l. A method of opening and tufting agglomerations of fibrous material comprising discharging the agglomerations between a rotary brush and in obstructed surface to subject the agglomera- 51011.8 therebetween to a rolling, shearing and tearing action.

2. A method of opening and tufting mineral wool nodules and of distributing a powdered binder therein comprising delivering the nodules to a restricted zone between a rotating brush and a semi-cylindrical surface generally concentric to the brush and including a roughened section to subject the nodules 'therebetween to a rolling, shearing and tearing action whereby the nodules are opened and the treating material is spread over the fibers thereof.

3. A method of opening and tufting mineral wool nodules and of distributing the open nodules on a receiving surface comprising delivering the nodules to a confined zone between a rotating brush and a surface including a roughened section to subject the nodules in said zone to a rolling, shearing and tearing action whereby the nodules are opened and tufted, and discharging the opened nodules from said zone under the impetus of said rotating brush to distribute the nodules on a receiving surface.

4. A method of opening and tufting mineral wool nodules and of distributing the nodules on a receiving surface comprising delivering the nodules carrying a powdered binder to a restricted zone between a rotating brush and a semi-cylindrical surface generally concentric to the brush and having in part a roughened surface composed of the material of the nodules to subject the nodules in said zone to a rolling, shearing and tearing action whereby the nodules are opened and the treating material is spread over the fibers, and

discharging the opened nodules from said zone under the impetus of said rotating brush to distribute them on a receiving surface.

5. A method of opening and tufting agglomerations of fibrous material comprising discharging the agglomerations between a rotary brush and a toothed surface to subject the agglomerations therebetween to a rolling, shearing and tearing action.

6. An apparatus for opening and tufting fibrous nodules comprising a cylindrical continuous brush mounted for rotation, a semi-cylindrical memberadjacent said brush and spaced substantially uniformly therefrom to define a restricted zone for the agglomerations or nodules, a forward end on said member, a ballie positioned adjacent said forward end within said zone and extending toward said brush to define a discharge port, means for delivering nodules to the zone and means for rotating the brush.

7. An apparatus for opening and tufting fibrous nodules comprising a cylindrical continuous brush mounted for rotation, a semi-cylindrical member adjacent said brush and spaced substantially uniformly from the periphery thereof to define an arcuate, restricted zone, a forward end on said member, a baflie positioned adjacent said forward end within said zone and extending toward said brush to define a discharge port, means for delivering nodules to the zone and means for rotat-=v ing the brush.

8. An apparatus for opening and tufting fibrous nodules comprising a cylindrical continuous brush mounted for rotation, a semi-cylindrical member adjacent said brush and spaced therefrom to define a restricted zone, a forward end on said member, a bafiie adjacent said forward end and extending toward said brush to define a discharge port, means for delivering fibrous nodules to the zone adjacent the end thereof opposite said port,

means for rotating said brush, a deflector plate hingedly connected to said semi-cylindrical member adjacent the discharge port to control the discharge of the nodules discharged through said port, and means for adjustably positioning said deflector plate.

JOSEPH H. ZE'I'I'EL.

REFERENCES CITED The following references are of record in the file of this patent:

UNITED STATES PATENTS Number Name Date Re. 16,449 Von Osten Oct. 26, 1926 36,923 Storms Nov. 11, 1862 85,024 Owen Dec. 15, 1868 463,330 Cunningham Nov. 17, 1891 830,646 Davis Sept. 11, 1906 1,355,518 Von Osten Oct. 12, 1920 1,483,049 Sturtevant Feb. 5, 1924 1,691,196 Jirotka Nov. 13, 1928 1,750,725 Miller Mar. 18, 1930 1,925,162 Wilson Sept. 5, 1933 1,976,382 Blewett Oct. 9, 1934 2,054,301 Richter Sept. 15, 1936 2,217,538 Carson Oct. 8, 1940 2,219,285 Allen et a1. Oct. 29, 1940 2,372,433 Koon Mar. 27, 1945 2,375,284 Coss May 8, 1945" 

2. A METHOD OF OPENING AND TUFTING MINERAL WOOL NODULES AND OF DISTRIBUTING A POWDERED BINDER THEREIN COMPRISING DELIVERING THE NODULES TO A RESTRICTED ZONE BETWEEN A ROTATING BRUSH AND A SEMI-CYLINDRICAL SURFACE GENERALLY CONCENTRIC TO THE BRUSH AND INCLUDING A ROUGHENED SECTION TO SUBJECT THE NODULES THEREBETWEEN TO A ROLLING SHEARING AND TEARING ACTION WHEREBY THE NODULES ARE OPENED AND THE TREATING MATERIAL IS SPREAD OVER THE FIBERS THEREOF. 